JP2015155588A - Manufacturing method and manufacturing apparatus of three dimensional net-like structure - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a three dimensional net-like structure manufacturing apparatus capable of preventing defective forming of a three dimensional net-like structure, improving versatility to manufacture various shapes and sizes of three dimensional net-like structures, and extending life of the manufacturing apparatus.

SOLUTION: A three dimensional net-like structure manufacturing apparatus comprises: a cap 370 with multiple push-out holes for pushing out and dropping melted thermoplastic resin as filaments 310; a water bath 390 for cooling an aggregation 311 of the filaments 310; conveyors 340a, 340b placed to face each other below the push-out holes 371, around which endless members 341 are placed with a gap R between them; ejecting holes 320 for ejecting cooling water from the gaps R toward the aggregation 311, which is placed at inner regions I of the conveyors 340a, 340b; and a guide 330, which is placed at the inner region I and regulates deflection of the endless members 341. The aggregation 311 is formed into a three dimensional net-like structure 315 by taking out the aggregation 311 by conveyors 340a, 340b at a lower speed than dropping speed of the filaments 310 and cooling the aggregation 311 in the water bath 390.

COPYRIGHT: (C)2015,JPO&INPIT

Description

  The present invention relates to a three-dimensional network structure manufacturing method and a three-dimensional network structure manufacturing apparatus used for mattresses, cushions and the like.

  A conventional two- or four-sided molding method for a three-dimensional network structure, and an irregularly shaped shape are those shown in Patent Document 1, and a die having a plurality of holes is formed from a molten filament made of a thermoplastic resin as a raw material or a main raw material. When manufacturing a three-dimensional network structure by pushing down from a die at the tip, partially submerged, naturally descending between the take-up machines, and drawing the filaments slower than the descent speed, the take-up machines are mutually connected There is at least one pair facing each other, and a predetermined shape such as a quadrilateral is formed in a direction perpendicular to the extrusion direction by the pair of take-up machines, and the take-up machines are opposed to each other by the width of the aggregate of the extruded filaments Is formed by contacting the take-up machine with two or four outer peripheral surfaces of the filament assembly before and after the take-out machine is submerged, and the outer four sides are parallel to the extrusion direction. Surface side Degree is a method of molding a three-dimensional net-like structure characterized by relatively higher that than the density of the portion excluding the surface side. This eliminates the need for finishing in the subsequent process and increases the degree of alignment.

JP 2001-328153 A

  However, there is a problem that the water temperature of the water tank rises due to continuous production of the three-dimensional network structure and normal cooling is not performed. This is particularly noticeable in the take-up path of a three-dimensional network structure that is important for cooling, and by delaying the cooling and solidification of the melted filament, the shape of the loop and the entangled portion collapses, resulting in poor formation of the three-dimensional network structure. There was a risk of inviting. Moreover, there existed a possibility of causing the damage of a manufacturing apparatus by the local water temperature rise in a water tank.

  Another problem is that the force applied to the take-up machine for the three-dimensional network structure is large due to the repulsive force of the assembly of the filaments being taken up, and if a conveyor with an endless member is used as the take-up machine, the conveyor May be bent and cannot be taken out, which may cause an obstacle to the production of a stable three-dimensional network structure, or may deteriorate the accuracy of the three-dimensional network structure. Generally, it is important to set the tension of a conveyor because of its structure. However, the optimal tension varies depending on various conditions and it is not easy to set the tension. Due to the unique structure of sandwiching and pulling the net-like structure, there is a risk that it will be even more difficult. For example, such a problem may become prominent when the width of the three-dimensional network structure is wide, such as when used as a mattress having a double bed size.

  Therefore, the present invention ensures the necessary cooling during the production of the three-dimensional network structure, prevents the formation failure of the three-dimensional network structure, and is versatile enough to adapt to the shape and size of various three-dimensional network structures. It is an object to improve the life of the manufacturing apparatus.

  In addition, the present invention prevents the conveyor from being bent by the repulsive force of the aggregate of the filaments being picked up, maintains the accuracy of the three-dimensional network structure, and makes various shapes and sizes of the three-dimensional network structure. Another object is to improve the versatility that can be handled and to extend the life of manufacturing equipment.

  In view of the above problems, the present invention provides a base having a plurality of extrusion holes for extruding and lowering a molten thermoplastic resin as a filament, a water tank for cooling the aggregate of the filaments, and below the extrusion hole. A pair of opposingly provided and endless members provided in the periphery have a gap, and an ejection hole provided in an inner region of the conveyor to eject cooling water from the gap toward the aggregate or the aggregate A forced convection member including at least one of suction holes for sucking water from the vicinity through the gap, and the assembly is taken up by the conveyor at a speed lower than the descending speed of the filament, and cooled by the water tank. , A three-dimensional network structure manufacturing apparatus that makes the aggregate a three-dimensional network structure.

  Further, the present invention provides a die having a plurality of extrusion holes for extruding and lowering molten thermoplastic resin as a filament, a water tank for cooling the aggregate of the filament, and a pair facing below the extrusion hole A circumferentially provided endless member having a gap, and a guide that is provided in an inner region of the conveyor and that restricts the bending of the endless member, and is slower than the descending speed of the filament Then, the assembly is taken up by the conveyor and cooled in the water tank, thereby forming the assembly into a three-dimensional network structure.

  Further, the present invention provides a die having a plurality of extrusion holes for extruding and lowering molten thermoplastic resin as a filament, a water tank for cooling the aggregate of the filament, and a pair facing below the extrusion hole The endless member provided around the conveyor has a gap, and is provided in an inner region of the conveyor, and the jet hole for ejecting cooling water from the gap toward the assembly or the vicinity of the assembly A forced convection member including at least one of suction holes for sucking water through the gap, and a guide provided in the inner region for restricting the bending of the endless member, and at a speed slower than the descending speed of the filament The apparatus is a three-dimensional network-structure manufacturing apparatus that takes the aggregate by the conveyor and cools it in the water tank to make the aggregate into a three-dimensional network structure.

  The present invention also opposes an extrusion step of extruding and lowering molten thermoplastic resin as a plurality of filaments, with the filament contacting the water surface or sandwiching the aggregate of the filaments descending. A loop forming step in which a pair of guide members or a conveyor facing below the guide members is contacted, the filaments are entangled irregularly, and the entangled portions are heat-welded, and the assembly is sandwiched by the conveyor A step of taking the water into the water at a speed slower than the descending speed of the wire, and an inner region of the conveyor toward a take-up region sandwiched between a pair of the conveyors, with an endless member provided around the conveyor having a gap Forced water convection occurs by ejecting cooling water from the gap through the gap or suctioning water through the gap from the take-up area to the interior area of the conveyor. Wherein a method of producing a three-dimensional net-like structure characterized by comprising a cooling step in parallel with the take-off step of cooling the aggregates in water, a.

  The present invention also opposes an extrusion step of extruding and lowering molten thermoplastic resin as a plurality of filaments, with the filament contacting the water surface or sandwiching the aggregate of the filaments descending. A loop forming step of contacting a pair of guide members or a conveyor facing below the guide members, wherein the filaments are entangled irregularly, and the entangled portions are heat-welded, and an endless member provided around the conveyor A guide for restricting bending in the inner region of the sheet, the take-up step of holding the assembly by the conveyor and taking it into the water at a speed slower than the descending speed of the filament, and the assembly in parallel with the take-up step And a cooling step for cooling in water.

  The present invention also opposes an extrusion step of extruding and lowering molten thermoplastic resin as a plurality of filaments, with the filament contacting the water surface or sandwiching the aggregate of the filaments descending. A loop forming step of contacting a pair of guide members or a conveyor facing below the guide members, wherein the filaments are entangled irregularly, and the entangled portions are heat-welded, and an endless member provided around the conveyor A guide step for restricting bending in the inner region of the sheet, the take-up step of holding the assembly by the conveyor and taking it into the water at a speed slower than the descending speed of the filament, and the endless member having a gap, Cooling water is ejected through the gap from the inner area of the conveyor toward the take-up area sandwiched by the conveyor, or the gap is passed from the take-up area to the inner area of the conveyor. A method for producing a three-dimensional network structure, comprising: forcibly convection of water by sucking water; and a cooling step for cooling the aggregate in water in parallel with the take-up step. .

  In the present invention, the melted thermoplastic resin is extruded downward as a plurality of filaments, and the filaments come into contact with the water surface, or a pair of guide members facing each other with the aggregate of the filaments descending between them. Contacting the opposite conveyor below the guide member, the filaments are entangled irregularly, the entangled portion is thermally welded to form a loop, the assembly is sandwiched by the conveyor, the wire of the filament The endless member that is drawn into the water at a speed slower than the descending speed and has a gap between the endless members disposed around the conveyor has a gap, and cooling water is passed through the gap from the inner area of the conveyor toward the take-up area sandwiched between the pair of conveyors A three-dimensional network structure in which forced convection of water occurs and is cooled in water when water is sucked through the gap from the take-up area to the inner area of the conveyor. .

  In the present invention, the melted thermoplastic resin is extruded downward as a plurality of filaments, and the filaments come into contact with the water surface, or a pair of guide members facing each other with the aggregate of the filaments descending between them. Contacting the opposite conveyor below the guide member, the filaments are entangled irregularly, the entangled portion is thermally welded to form a loop, in the inner region of the endless member provided around the conveyor It is a three-dimensional network-like structure in which the assembly is sandwiched by the conveyor provided with a guide for restricting bending, and is taken up in water and cooled at a speed slower than the descending speed of the filament.

  In the present invention, the melted thermoplastic resin is extruded downward as a plurality of filaments, and the filaments come into contact with the water surface, or a pair of guide members facing each other with the aggregate of the filaments descending between them. Contacting the opposite conveyor below the guide member, the filaments are entangled irregularly, the entangled portion is thermally welded to form a loop, in the inner region of the endless member provided around the conveyor The assembly is sandwiched by the conveyor having a guide for controlling bending and taken up in water at a speed slower than the descending speed of the filament, and an endless member provided around the conveyor has a gap, and a pair of the Cooling water is ejected through the gap from the inner area of the conveyor toward the take-off area sandwiched by the conveyor, or water is sucked through the gap from the take-up area to the inner area of the conveyor And by, occur forced convection of water, a three-dimensional net-like structure formed is cooled in water.

  In this invention, it is preferable that the said guide is a circular guide provided coaxially with the rotary body which drives the said endless member, and controls the bending of the said endless member.

  It is also preferable that the guide is an intermediate guide that extends in the longitudinal direction parallel to the straight portion of the endless member on the side of the inner region that contacts the assembly.

  The conveyor is formed by an endless member that circulates, and the endless member is preferably configured by a plate member connected in a vertical direction by a connecting member and provided circumferentially. The connecting member refers to an endless chain or the like. In addition, as the endless member, an endless belt made of rubber or metal mesh can be used.

  The internal area of the conveyor refers to an internal area separated by the circumferential arrangement of endless members. The take-up area is an area that is sandwiched between a pair of opposed conveyors among outer areas that are defined in the same manner as the inner area, and that passes through when the assembly is taken up. .

  The conveyor is provided so that the circumferential direction is provided up and down, and a pair of opposed conveyors are respectively conveyed downward in the take-up area.

  The rotating body is for driving the connecting member, and means a driving rotating body such as a pulley or a sprocket or a driven rotating body.

  According to the present invention, it is possible to directly apply a cooling water flow to the aggregate composed of the filaments being taken up, to cool more quickly and reliably, and to improve the formation of a three-dimensional network structure. can do. By continuously supplying fresh cooling water, an increase in water temperature can be prevented even during long-time operation of the apparatus. Further, by circulating low-temperature water in the lower part of the water tank, it is possible to prevent a local temperature increase in the take-up area important for cooling.

  According to the present invention, the bending of the endless member is restricted by the guide, and a highly accurate three-dimensional network structure can be stably manufactured. Even when a wide three-dimensional network structure such as a double bed-size mattress is manufactured, the endless member can be bent by the guide.

4 is a plan view in which the chute 80a, 80b of the manufacturing apparatus 1 for a three-dimensional network structure 15 according to the first embodiment is omitted. The left half of the water tank 90 and the base 70 are not shown. It is a top view of the manufacturing apparatus 1 of the three-dimensional network structure 15 by the Example 1. FIG. The left half of the water tank 90 and the base 70 are not shown. It is a left view of the manufacturing apparatus 1 of the three-dimensional network structure 15 by the Example 1. FIG. The left half of the water tank 90 and the base 70 are not shown. It is a front view of the nozzle | cap | die 70, chute | shoots 80a and 80b, and conveyors 40a and 40b part of the manufacturing apparatus 1 of the three-dimensional network structure 15 by the Example 1. FIG. It is a front view of the nozzle | cap | die 70 in the state which is operating the manufacturing apparatus 1 of the three-dimensional network structure 15 by the Example 1, chute | shoot 80a, 80b, and conveyor 40a, 40b part. FIG. 10 is a partial cross-sectional plan view in which the conveyors 240a and 240b of the manufacturing apparatus 201 for the three-dimensional network structure 215 according to the second embodiment are cross-sectionalized at the height of the upper drive shaft 244. The left half of the water tank 290 and the base 270 are not shown. It is a left view of the manufacturing apparatus 201 of the three-dimensional network structure 215 by the Example 2. FIG. The left half of the water tank 290 and the base 270 are not shown. It is a front view of the nozzle | cap | die 270, chute | shoot 280a, 280b, and conveyor 240a, 240b part of the manufacturing apparatus 201 of the three-dimensional network structure 215 by the Example 2. FIG. It is a front view of the nozzle | cap | die 270, the chute | shoots 280a and 280b, and the conveyors 240a and 240b in the state which is operating the manufacturing apparatus 201 of the solid network structure 215 by the Example 2. FIG. It is a front view of the nozzle | cap | die 370, chute | shoot 380a, 380b, and conveyor 340a, 340b part of the manufacturing apparatus 301 of the three-dimensional network structure 315 by Example 3. FIG. The relationship with the guide 330 in the conveyor 340a and the relationship with the ejection hole 320 in the conveyor 340b are illustrated, but this is for the sake of convenience, and there is no difference between these configurations in the conveyors 340a and 340b. . It is a front view of the nozzle | cap | die 370, the chute | shoots 380a and 380b, and the conveyors 340a and 340b part in the state which is operating the manufacturing apparatus 301 of the three-dimensional network structure 315 by the Example 3. FIG.

  A manufacturing apparatus 1 (hereinafter simply referred to as manufacturing apparatus 1) of a three-dimensional network structure 15 (see FIG. 5) according to Example 1 of the present invention will be described below with reference to FIGS. As shown in FIGS. 1 to 5, this manufacturing apparatus 1 sandwiches a base 70 having a plurality of extrusion holes 71 for extruding and lowering a molten thermoplastic resin as a filament 10 and a descending assembly 11. A pair of opposed chutes 80a and 80b, a water tank 90 that cools the assembly 11, and a pair are provided opposite to each other below the extrusion hole 71, and a circumferentially provided endless member 41 has a gap R. The conveyors 40a and 40b, and the ejection holes 20 that are provided in the inner region I of the conveyors 40a and 40b and eject the cooling water from the gap R toward the assembly 11, are slower than the descending speed of the filament 10. The aggregate 11 is taken up by the conveyors 40 a and 40 b and cooled in the water tank 90 while ejecting the cooling water through the ejection holes 20, thereby forming the aggregate 11 as the three-dimensional network structure 15. Hereinafter, each part will be described.

  First, the ejection hole 20 will be described. As shown in FIGS. 4 and 5, the ejection hole 20 is provided at the tip of the nozzle 21 provided in each of the inner regions I of the conveyors 40a and 40b, and passes through the gap R toward the take-up region U sandwiched between the conveyors 40a and 40b. The cooling water is set to be ejected. As shown in FIGS. 3 to 5, three nozzles 21 are provided in each of the upper frame 50 and the lower frame 51 extending in the lateral direction in the inner region I of the conveyors 40 a and 40 b, and these are provided in the supply pipe 22. In communication, cooling water is supplied from an external water source (not shown). The amount of water from each ejection hole is preferably set to 2 to 50 liters / minute by a pump (not shown), more preferably set to 4 to 40 liters / minute, and set to 6 to 20 liters / minute. More preferably. The internal area I is an internal area separated by the endless member 41 in the conveyors 40a and 40b, and the take-up area U is an area sandwiched between the pair of conveyors 40a and 40b, and the assembly 11 is taken up. An area that passes through. The configuration of the conveyors 40a and 40b and the assembly 11 will be described later.

  The location where the ejection holes 20 are provided is not limited to the illustrated locations, and can be selected as appropriate in the internal region I. In other words, the ejection holes 20 are not limited to the intermediate portions of the conveyors 40a and 40b as illustrated, and may be provided at the upper and lower portions of the conveyors 40a and 40b, or may be provided at a plurality of these locations. Moreover, although the jet hole 20 is provided in six places on one side, the number is not limited and at least one place, preferably 2 to 6 places are provided for a pair of conveyors. Further, fresh water is supplied to the nozzle 21 from an external water source (not shown). However, the present invention is not limited to this. For example, relatively low-temperature water such as a lower part of the water tank 90 is taken in, and a circulation pump (not shown). It is good also as stirring the inside of the water tank 90, for example by connecting a water flow to the nozzle 21 and supplying it from the ejection hole 20.

  If the ejection holes 20 are set to be smaller than the vertical interval of the gap R, it is preferable that the loss of water pressure can be reduced and the inside of the assembly 11 can be effectively cooled. In this embodiment, the endless member 41 provided around the conveyors 40a and 40b is constituted by a plate member 42 which is elongated in the horizontal direction and connected in the vertical direction by an endless chain 43 which is a connecting member. Since the gap R is provided as a vertical interval of the plate member 42, the gap R is set to a smaller ejection hole 20 than this.

  The endless member 41 included in each of the pair of conveyors 40a and 40b is configured by a plate member 42 which is long in the horizontal direction connected in the vertical direction by an endless chain 43 and provided circumferentially as shown in FIGS. The As shown in FIGS. 2 to 4, one of the pair of conveyors 40a and 40b includes an upper drive shaft 44 and a lower drive shaft 45, which rotate between the front frame 46a and the rear frame 47a. It is pivotally supported. Similarly, the other conveyor 40b of the pair of conveyors 40a and 40b includes an upper drive shaft 44 and a lower drive shaft 45, which are pivotally supported between a front frame 46b and a rear frame 47b. The Between the front frames 46a, 46b and the back frames 47a, 47b, an upper frame 50 and a lower frame 51 extend in the lateral direction in the inner region I of the conveyors 40a, 40b. Between the upper drive shaft 44 and the lower drive shaft 45 and between the upper drive shaft 44 and the lower drive shaft 45, an upper sprocket 48 and a lower sprocket 49 are provided at corresponding intervals, respectively. The sprocket 48 and the lower sprocket 49 are provided with tension. In addition, as the endless member 41, an endless belt having a mesh made of rubber or metal can be used in addition to the above configuration. Note that the teeth of the upper sprocket 48 and the lower sprocket 49 in FIGS. 3 to 5 are omitted.

  The plate material 42 is preferably made of metal, but may be ceramic, heat resistant plastic, carbon fiber, FRP, or a composite material thereof. For example, a plastic plate may be laminated on a metal surface so that the filament contacts the plastic surface.

  The conveyor 40a is connected to a drive control device (not shown) including a drive motor, a drive chain, various gears, a transmission, a control device, and other instruments, and thereby the rotational drive force is applied to the upper drive shaft 44. Is granted. This rotational driving force is simultaneously transmitted to the lower drive shaft 45, and the upper drive shaft 44 and the lower drive shaft 45 rotate synchronously (see FIG. 4).

  The pair of conveyors 40a and 40b are provided in the water tank 90 while being sandwiched between the front frame 46a and the back frame 47a, the front frame 46b and the back frame 47b, respectively, as shown in FIGS. Although the front frame 46a and the back frame 47a are fixed inside the water tank 90, the front frame 46b and the back frame 47b slide to the left and right inside the water tank 90, and the facing distance C1 between the pair of conveyors 40a and 40b can be adjusted. It is said.

  Although illustration is omitted, an interval adjusting mechanism that can adjust the opposing interval C1 of the pair of conveyors 40a and 40b may be provided. For example, it can be configured with a shaft, a handle, a gear, and the like, and includes a configuration in which one of the pair of conveyors 40a and 40b is horizontally moved along the shaft. The mechanical transmission of the position adjustment in the interval adjustment mechanism is merely an example, and other configurations can be adopted. For example, a bevel gear or a worm gear may be used as the gear.

  The facing interval C1 between the pair of conveyors 40a and 40b is set narrower than the interval S1 between the lower ends of the chutes 80a and 80b (see FIG. 4). The facing interval C1 is preferably narrowed by 1 to 13% with respect to the interval S1. If it is smaller than 1%, the effect of improving the repulsive force of the product and the stability of the thickness is small, and if it is larger than 13%, the trace of the plate material 42 remains on the product or the burden on driving the conveyors 40a and 40b increases. Because it will end up. Further, the facing interval C1 is more preferably 2 to 10% narrower than the interval S1, and further preferably 3 to 7% narrower.

  As shown in FIG. 4, the base 70 has a plurality of extrusion holes 71 arranged in a substantially long quadrilateral, and the line 10 is lowered downward by applying pressure to the molten thermoplastic resin and discharging it. It is something to be made. A plurality of extrusion holes 71 are arranged in a substantially long quadrilateral. Since a plurality of the extrusion holes 71 are arranged, the group of filaments becomes the aggregate 11 having the arrangement shape of the extrusion holes 71 as a cross-sectional shape in the descending direction. The descending assembly 11 has two long sides and two short sides on the outer periphery.

  The chute | shoots 80a and 80b are a pair of guide members arrange | positioned so that it may oppose on both sides of the longitudinal side of the assembly 11 to descend | fall below the nozzle | cap | die 70, as shown in FIG. 4, FIG. The pair of chutes 80a and 80b each have a shape inclined downward toward the assembly 11, and the interval S1 at which the lower ends thereof are opposed is the same as the arrangement interval D1 in the short direction of the extrusion holes 71 in the base 70, or It is set narrower than.

  Moreover, as shown in FIG. 1, the short chutes 81a and 81b are arranged so as to face each other with the short side surface of the aggregate 11 interposed therebetween. Although the short shoots 81a and 81b are shown in FIG. 1 which is a plan view, the structure of the inclination and the like is the same as the chutes 80a and 80b shown in FIGS. The interval at which the lower ends of the short chutes 81 a and 81 b face each other is set to be narrower than the arrangement interval in the longitudinal direction of the extrusion holes 71 in the base 70. The present invention can be applied without using the chutes 80a and 80b and the short chutes 81a and 81b.

  A region surrounded by the lower ends of the chutes 80a and 80b extending in the longitudinal direction and the lower ends of the short chutes 81a and 81b is a molding opening 82 which is the minimum cross-sectional area through which the assembly 11 passes (FIG. 1). reference). The shape of the inclined surface is not limited to that shown in FIGS. 4 and 5, and may be a single flat inclined surface or a curved surface with a changing inclination rate. The chutes 80a and 80b and the short chutes 81a and 81b extending in the longitudinal direction may be provided independently, or may be provided continuously and integrally at four orthogonal corners.

  A water supply port 83 is provided above the chutes 80a and 80b. A plurality of water supply ports 83 are provided at appropriate intervals in the supply pipes 84a and 84b extending over almost the entire width in the longitudinal direction of the chutes 80a and 80b. As shown by an arrow W in FIG. Supply. The supply of the water flow to the short chutes 81a and 81b may be diverted by adjusting the water flow from the supply pipes 84a and 84b, or a similar supply pipe (not shown) is provided above the short chutes 81a and 81b. ) May be provided.

  The water tank 90 is for cooling the aggregate 11, and has a size that can be adjusted to a water level at which the entire conveyors 40a and 40b are submerged. The water level may be set so that the upper portions of the conveyors 40a and 40b are on the water. The water level H (see FIG. 4) relative to the lower ends of the chutes 80a and 80b is preferably set to 0 ≦ Wd ≦ 30 (mm), more preferably set to 1 ≦ Wd ≦ 20 (mm). More preferably, the height is set to 3 ≦ Wd ≦ 12 (mm). The water level includes the same height as the lower ends of the chutes 80a and 80b, and the present invention can be implemented if the water level is higher than this. However, it is preferable to set the water level height in consideration of variations in the water level at the time of manufacture and the level of the machine. Although affected by the manufacturing conditions, if the water level is set to a height of 3 mm or more, the water level can be prevented from becoming lower than the lower ends of the chutes 80a and 80b. On the other hand, when the water level exceeds 30 mm from the lower ends of the chutes 80a and 80b, depending on the conditions, the resin starts to be solidified and the fibers are poorly fused, and the surface roughness increases, which is inappropriate.

  Hereinafter, the manufacturing method of the three-dimensional network structure by Example 1 of this invention is demonstrated with reference to FIG. The detailed description of known components is omitted, so Japanese Patent No. 4350286, U.S. Pat. S. Patent No. See 7,625,629 and the like.

  First, a raw material mainly composed of a thermoplastic synthetic resin is melted. The melted raw material is sent into the base 70, pressure is applied, and it is extruded downward from the lower extrusion hole 71 to become the filament 10. The temperature range inside the base 70 can be set to 100 to 400 ° C., the extrusion amount can be set to 20 to 200 Kg / hour, and the like. The pressure in the base 70 is, for example, that due to the discharge pressure of a 75 mm screw, and the pressure range is about 0.2 to 25 MPa. When manufacturing the three-dimensional network 15 having a thickness exceeding 100 mm, it is preferable to make the die pressure uniform by a gear pump or the like. Each of the filaments 10 discharged from the base 70 becomes an aggregate 11 composed of a plurality of filaments 10 due to a plurality of arrangements of the extrusion holes 71.

  As shown in FIG. 5, the filament 10 positioned on the outer peripheral longitudinal side surface of the aggregate 11 is grounded on the pair of chutes 80 a and 80 b, and the vertical drop trajectory is disturbed by the contact, and the adjacent filament 10 While entangled in a loop shape, it rides on the water flow supplied from the supply pipes 84a and 84b and slides down on the chute 80a and 80b. At this time, the filament 10 is directly affected by gravity and is intertwined two-dimensionally along the chutes 80a and 80b. The water flow supplied from the supply pipes 84a and 84b also reaches the pair of short chutes 81a and 81b, and the line 10 located on the short side surface of the outer periphery of the aggregate 11 is similarly short chutes 81a and 81b. Will slide down.

  Of the aggregate 11, the filament 10 that has fallen without contacting any of the chutes 80a and 80b and the short chutes 81a and 81b extending in the longitudinal direction passes through the forming opening 82. At this time, among the filaments 10 that pass through the molding opening 82, those that pass near the lower ends of the chutes 80a and 80b and the short chutes 81a and 81b slide down the chutes 80a and 80b and the short chutes 81a and 81b. It comes into contact with the coming wire 10 and is entangled in a loop shape, and further, the disturbance of the drop trajectory due to the contact entanglement propagates to the adjacent wire 10 in the central direction and falls. Of the filaments 10 that pass through the molding opening 82, those that pass near the center of the molding opening 82 land on the water surface without being entangled as described above (see FIG. 5). Here, since the take-up speed by the conveyors 40a and 40b is slower than the dropping speed of the aggregate 11, the landed wire 10 is bent and entangled in a loop shape near the water surface.

  In this way, the aggregate 11 has a three-dimensional network structure and is taken down by the conveyors 40a and 40b while being cooled in the water tank 90. The assembly 11 lowered to the position of the minimum facing interval of the conveyors 40a and 40b is sandwiched and compressed by the conveyors 40a and 40b at the facing interval C1 smaller than the interval S1 in the short direction of the forming opening 82 (see FIG. 5). At the time when the conveyors 40a and 40b are lowered to the position of the minimum facing interval, the cooling and solidification of the assembly 11 due to submersion is not yet complete, so that a compression molding effect can be obtained by sandwiching with the conveyors 40a and 40b. It is.

  The assembly 11 lowered to the position of the ejection hole 20 in the take-up area U receives the cooling water ejected by the ejection hole 20 from the inner area I of the conveyors 40a and 40b through the gap R of the endless member 41 (see FIG. 5). . The cooling of the aggregate 11 starts from the point of time when it reaches the water tank 90, but the cooling inside the aggregate 11 may be delayed, but it is surely cooled by the cooling water from the ejection holes 20. Then, if it picks up and conveys by the conveyors 40a and 40b, the aggregate | assembly 11 formed in the solid network structure will progress cooling, and a shape will be fixed.

  The three-dimensional network structure 15 can be obtained by continuing the above operation, pulling out the assembly 11 in the left direction of the water tank 90, pulling it out from the water tank 90, and cutting it to a desired length. The three-dimensional network structure 15 has a shape similar to that of the molding opening 82 in a cross-section, and has a substantially plate shape in a state of being subjected to auxiliary compression molding by the conveyors 40a and 40b. In addition, when the short chutes 81a and 81b are not provided, the end surface treatment of the short side surface of the three-dimensional network structure 15 is performed as necessary. In addition, when not using chute | shoots 80a and 80b, it will land while contacting the conveyors 40a and 40b directly, but the three-dimensional network structure 15 is formed like the above.

  As a thermoplastic resin as a raw material of the three-dimensional network structure 15 according to the present invention, a polyolefin such as polyethylene and polypropylene, a polyester such as polyethylene terephthalate, a polyamide such as nylon 66, polyvinyl chloride, polystyrene, a copolymer based on the above resin, Examples include elastomers and blends of the above resins. Blended raw materials such as antibacterial agents are also possible. For example, when the three-dimensional network structure 15 is used as a bedding mattress, polyethylene is suitable as the raw material. Moreover, an antibacterial agent, a non-combustible material, and a flame retardant may be mixed with the raw material thermoplastic resin so that the three-dimensional network structure 15 has these functions.

  The three-dimensional network structure 15 manufactured by Example 1 of the present invention will be described. In the three-dimensional network structure 15, the molten thermoplastic resin is extruded downward as a plurality of filaments 10, and the filaments 10 are in contact with the water surface 91, or are opposed to each other with the aggregate 11 of the filaments 10 that descend. The pair of chutes 80a, 80b or the conveyors 40a, 40b come into contact with each other, the filaments 10 are irregularly entangled, the entangled portions are thermally welded to form a loop, and the assembly 11 is held by the conveyors 40a, 40b. It is drawn into the water at a speed slower than the descending speed of the filament 10, and the cooling water is ejected from the inner area I of the conveyors 40a, 40b toward the take-up area U through the gap R and cooled in the water. . As a result, the three-dimensional network structure 15 has a three-dimensional network structure in which a plurality of filaments 10 are randomly entangled in a loop shape and thermally bonded. In the three-dimensional network structure 15, a surface portion 16 having a larger bulk density than the inner portion 17 is formed on the side surfaces corresponding to the long side surface and the short side surface of the outer peripheral portion of the assembly 11 at the manufacturing stage. The surface portion 16 is due to the two-dimensional entanglement of the filament 10 along the chutes 80a and 80b in the manufacturing stage.

  The effect by Example 1 of this invention is demonstrated. By ejecting the cooling water from the ejection hole 20 toward the take-up region U, the assembly 11 being taken up can be reliably cooled. Thereby, formation defects due to insufficient cooling of the three-dimensional network structure 15 can be prevented, and the manufacturing efficiency can be improved.

  By continuously supplying fresh cooling water from the ejection holes 20, it is possible to prevent an increase in water temperature even during long-time operation of the manufacturing apparatus 1 and to stabilize the quality of the three-dimensional network structure 15. In addition, by circulating water at a low temperature in the water tank 90, it is possible to prevent a local temperature increase in the take-up region important for cooling and to keep the formation of the three-dimensional network structure 15 well.

  By preventing an overall temperature rise or a local temperature rise in the water tank 90, thermal damage to the manufacturing apparatus can be prevented and the life can be extended.

  In the three-dimensional network structure 15 according to the first embodiment, the surface portion 16 is formed, so that the cooling of the inside 17 is difficult to proceed, but the cooling water is ejected from the ejection hole 20 toward the take-up region U. By doing so, it becomes possible to apply cooling water directly to the inside 17. In addition, forced convection of water occurs due to the ejected water, and heat exchange is efficiently performed between the three-dimensional network structure and water. Further, when the assembly 11 is cooled by a die having a modified cross-section or when the three-dimensional network structure 15 is thick, the cooling of the interior 17 is difficult to proceed as in the case of forming the surface portion 16. However, the inside 17 can be appropriately cooled. That is, by ejecting cooling water from the ejection holes 20, versatility corresponding to the bulk density, shape, size, and the like of various three-dimensional network structures 15 is improved.

  As a modification of the first embodiment, the ejection hole 20 can be changed to a suction hole (not shown). The suction hole is connected to the pump by a suction pipe, and sucks water from the take-up area ∪ to the inner area I through the gap R. The water whose temperature has risen locally in the vicinity of the aggregate 11 in the take-up region U is sucked by the suction holes, and relatively cool water is supplied from the surroundings by forced convection of water. Therefore, heat exchange is efficiently performed between the three-dimensional network structure and water, and the inside 17 can be appropriately cooled. The sucked water may be supplied to the lower part of the water tank 90 and circulated, or may be discharged to the outside. Moreover, you may provide both a suction hole and an ejection hole.

  A manufacturing apparatus 201 (hereinafter simply referred to as a manufacturing apparatus 201) for a three-dimensional network structure 215 according to a second embodiment of the present invention will be described below with reference to FIGS. The manufacturing apparatus 201 is a pair of guide members opposed to each other with a die 270 having a plurality of extrusion holes 271 for extruding and lowering a molten thermoplastic resin as a filament 210 and sandwiching the descending filament assembly 211. Chute 280a, 280b, water tank 290 for cooling the filament aggregate 211, a pair of opposed endless members 241 provided below the extrusion hole 271, and conveyors 240a, 240b having a gap, conveyors 240a and 240b, and a guide 230 that restricts the bending of the endless member 241. The assembly 211 is taken up by the conveyors 240a and 240b at a speed lower than the descending speed of the filament 210. By cooling, the aggregate 211 becomes a three-dimensional network structure 215. Hereinafter, each part will be described.

  The guide 230 extends in the longitudinal direction parallel to the straight portion of the endless member 241 on the side of the inner region I that contacts the assembly 211. A circular guide (not shown) is provided on the upper drive shaft 244 and the lower drive shaft 245 that are coaxial with the upper sprocket 248 and the lower sprocket 249 that are rotating bodies that drive the endless member 241, and restricts the bending of the endless member 241. May be. The internal region I is an internal region separated by the endless member 241 in the conveyors 240a and 240b. Hereinafter, after describing the configuration of the conveyors 240a and 240b, the guide 230 will be described.

  As shown in FIG. 8, the endless member 241 provided in each of the pair of conveyors 240 a and 240 b is configured by a plate member 242 that is elongated in the horizontal direction and connected in the vertical direction by an endless chain 243. One conveyor 240a of the pair of conveyors 240a and 240b includes an upper drive shaft 244 and a lower drive shaft 245, which are pivotally supported between the front frame 246a and the rear frame 247a. Similarly, the other conveyor 240b of the pair of conveyors 240a and 240b includes an upper drive shaft 244 and a lower drive shaft 245, which are pivotally supported between the front frame 246b and the rear frame 247b. The Between the front frames 246a and 246b and the back frames 247a and 247b, an upper frame 250 and a lower frame 251 extend in the lateral direction in the inner region I of the conveyors 240a and 240b. Between the upper drive shaft 244 and the lower drive shaft 245 and between the upper drive shaft 244 and the lower drive shaft 245, an upper sprocket 248 and a lower sprocket 249 are provided at corresponding intervals, respectively. The sprocket 248 and the lower sprocket 249 are provided with tension. The endless member 241 may be an endless belt having a rubber or metal mesh connected in addition to the above configuration. Note that the teeth of the upper sprocket 248 and the lower sprocket 249 in FIGS. 6 to 9 are omitted.

  Since the pair of conveyors 240a and 240b is the same as that of the first embodiment, the description thereof is omitted.

  The guide 230 extends in the longitudinal direction parallel to the straight portion of the endless member 241 on the side of the inner region I of each of the conveyors 240a and 240b that contacts the assembly 211, and regulates the bending of the endless member 241. It is. That is, the conveyors 240a and 240b are provided in the shape of a long oval and have two straight portions. Of these, the conveyors 240a and 240b pass between the pair of conveyors 240a and 240b when the assembly 211 is taken up. The guide 230 is provided in each of the inner regions I of the conveyors 240a and 240b, which are straight portions on the side in the take-up region U. As shown in FIG. 8, the guide 230 is fixed to the upper frame 250 and the lower frame 251 extending in the lateral direction in the inner region I of the conveyors 240 a and 240 b, and slides with respect to the rotating plate member 242. Provided. For the sake of convenience, FIG. 8 shows a partial cross-sectional shape at a position where the guide 230 can be seen on the front side of the endless chain 243. As shown in FIG. 7, three guides 230 are provided in the extending direction of the upper drive shaft 244 and the lower drive shaft 245. However, the guide 230 is not limited to this, and the size, shape, and bulk density of the three-dimensional network structure 215 to be manufactured are not limited thereto. -The quantity, position, shape, etc. can be adjusted as appropriate according to the repulsive force of the material. The material of the guide 230 is made of a hard resin, but a metal, a ceramic, a carbon fiber, a composite material, or the like may be used depending on the elements in the manufacturing.

  Hereinafter, since the manufacturing method of the three-dimensional network structure 215 according to the second embodiment of the present invention is the same as that of the first embodiment, the nozzle 20 and the nozzle 21 are omitted, and a guide 230 is provided. Since the thing is the same, description is used.

  The effect by Example 2 of this invention is demonstrated. In this embodiment, by providing the guide 230, it is possible to regulate the bending of the plate material 242 in the conveyors 240a and 240b and stably manufacture the three-dimensional network structure 215 with good accuracy.

  Further, by providing the guide 230, it is possible to prevent distortion of the plate material 242 when manufacturing the three-dimensional network structure 215 having various shapes and sizes. For example, when a wide three-dimensional network structure 215 such as a double bed size mattress is manufactured, the laterally extending length of the plate member 242 becomes large, and the repulsive force of the assembly 211 during taking-up causes the plate member 242 to be retreated. Although the bending stress to be applied also increases, by providing the guides 230 at appropriate intervals, the bending rigidity required for the plate material 242 can be maintained and the bending of the plate material 242 can be prevented. In addition, for example, in the line for manufacturing the three-dimensional network structure 215 having a long quadrangular cross-sectional shape by the base 270, when the shape of the three-dimensional network structure 215 to be manufactured is changed to an irregular shape, the assembly The repulsive force from 211 concentrates in the vicinity of the center in the extending direction of the plate member 242 and the bending stress applied to the plate member 242 increases. Even in such a case, the guide 230 can prevent the plate member 242 from being bent. it can.

  By providing the guide 230, the rigidity of the conveyors 240a and 240b as a whole is improved, and by providing the interval adjusting mechanism (not shown), the opposing interval C1 of the conveyors 240a and 240b can be adjusted. It is possible to set an optimum interval of the take-up region U in accordance with the shape and size, and keep this.

  As described above, by providing the guide 230, various three-dimensional network structures 215 can be accurately manufactured, and the versatility of the manufacturing apparatus 201 is improved. Further, in order to prevent the plate member 242 from being bent, an appropriate tension setting range of the endless chain 243 is widened, and the tension can be easily set. Furthermore, by improving the overall rigidity of the conveyors 240a and 240b, the burden on the tension of the endless chain 243 for maintaining the shape of the entire conveyors 240a and 240b can be reduced, and the life of the manufacturing apparatus 201 can be extended. The cost is reduced overall.

  In addition, by providing a circular guide (not shown), it is possible to prevent the plate material 242 from being bent at the upper and lower portions of the conveyors 240a and 240b. As described above, the distance C1 between the pair of conveyors 240a and 240b is set to be narrower than the distance S1 between the lower ends of the chutes 280a and 280b in order to take up the aggregate 211, and the manufacturing method of the above-described three-dimensional network structure 215 As described above, since the three-dimensional network structure is formed in the vicinity of the water surface 291 in the aggregate 211, the repulsive force for compressing the aggregate 211 on the conveyors 240a and 240b as the facing distance C1 between the conveyors 240a and 240b decreases. However, since circular guides (not shown) are provided on the upper portions of the conveyors 240a and 240b, the bending rigidity of the plate material 242 necessary for compressing the aggregate 211 can be maintained. In addition, since circular guides (not shown) are also provided at the lower parts of the conveyors 240a and 240b, the upper and lower rigidity of the conveyors 240a and 240b can be maintained in a well-balanced manner, and the force applied to the upper parts of the conveyors 240a and 240b can be maintained. The conveyors 240a and 240b are not distorted as a whole.

  A manufacturing apparatus 301 (hereinafter, simply referred to as a manufacturing apparatus 301) for a three-dimensional network structure 315 according to a third embodiment of the present invention will be described below with reference to FIGS. Since the manufacturing apparatus 301 is almost the same as in the first and second embodiments, the description is incorporated, but the jet outlet 320 in the first embodiment, the jet outlet 320 corresponding to the nozzle 21, the nozzle 321, and the guide 230 in the second embodiment. The difference is that the corresponding guides 330 are provided together. 10 and 11, each of the jet outlet 320, the nozzle 321, and the guide 330 includes a pair of left and right, but in the drawings, only one is shown for convenience and the others are omitted.

  The effect by Example 3 of this invention is demonstrated. In the third embodiment, since the ejection port 320, the nozzle 321 and the guide 330 are all provided, a synergistic effect can be obtained by providing both the effects of the first and second embodiments. As a modification, the ejection port 320 may be changed to a suction hole.

  Note that the present invention is not limited to the above-described embodiment, and modifications and the like can be made without departing from the technical idea of the present invention. It will be included in the technical scope of the present invention.

1, 201, 301... Three-dimensional network structure manufacturing apparatus 10, 210, 310... Lines 11, 211, 311... Aggregates 15, 215, 315. ... Eject holes 230, 330 ... Guides 40a, 40b, 240a, 240b, 340a, 340b ... Conveyors 41, 241, 341 ... Endless members 42, 242, 342 ... Plate material R ... gap

Claims (15)

A die having a plurality of extrusion holes for extruding and lowering the molten thermoplastic resin as a filament;
A water tank for cooling the assembly of the filaments;
A conveyer having a pair of opposed endless members provided below the extrusion hole and a circumferentially provided endless member having a gap;
A forced convection member provided in an inner region of the conveyor and including at least one of an ejection hole for ejecting cooling water from the gap toward the assembly or a suction hole for sucking water through the gap from the vicinity of the assembly; With
The three-dimensional network-structure manufacturing apparatus which makes the said aggregate | assembly into a three-dimensional network structure by taking up the said aggregate | assembly by the said conveyor at a speed slower than the descent | fall speed | rate of the said filament, and cooling with the said water tank. A die having a plurality of extrusion holes for extruding and lowering the molten thermoplastic resin as a filament;
A water tank for cooling the assembly of the filaments;
A conveyer having a pair of opposed endless members provided below the extrusion hole and a circumferentially provided endless member having a gap;
A guide that is provided in an inner region of the conveyor and regulates the bending of the endless member,
The three-dimensional network-structure manufacturing apparatus which makes the said aggregate | assembly into a three-dimensional network structure by taking up the said aggregate | assembly by the said conveyor at a speed slower than the descent | fall speed | rate of the said filament, and cooling with the said water tank. A die having a plurality of extrusion holes for extruding and lowering the molten thermoplastic resin as a filament;
A water tank for cooling the assembly of the filaments;
A conveyer having a pair of opposed endless members provided below the extrusion hole and a circumferentially provided endless member having a gap;
A forced convection member provided in an inner region of the conveyor and including at least one of an ejection hole for ejecting cooling water from the gap toward the assembly or a suction hole for sucking water through the gap from the vicinity of the assembly;
A guide that is provided in the inner region and restricts the bending of the endless member,
The three-dimensional network-structure manufacturing apparatus which makes the said aggregate | assembly into a three-dimensional network structure by taking up the said aggregate | assembly by the said conveyor at a speed slower than the descent | fall speed | rate of the said filament, and cooling with the said water tank.   The three-dimensional network structure manufacturing apparatus according to claim 2 or 3, wherein the guide is a circular guide that is provided coaxially with a rotating body that drives the endless member and restricts bending of the endless member.   4. The three-dimensional network structure manufacturing apparatus according to claim 2, wherein the guide is an intermediate guide that extends in a longitudinal direction parallel to the straight portion of the endless member on a side in contact with the assembly in the inner region. An extrusion step of extruding and lowering the molten thermoplastic resin downward as a plurality of filaments;
The filaments contact the water surface, or contact a pair of guide members facing each other across the descending assembly of the filaments or a conveyor facing below the guide members, and the filaments are entangled irregularly. Loop formation step in which the entangled portion is heat-welded,
A take-off step of sandwiching the assembly by the conveyor and taking it into the water at a speed slower than the descending speed of the filament;
The endless member provided around the conveyor has a gap, and the cooling water is ejected from the inner area of the conveyor toward the take-up area sandwiched between the pair of conveyors through the gap, or from the take-up area to the conveyor. A cooling step in which forced convection of the water is caused by sucking water through the gap into the inner region of the chamber and the assembly is cooled in water in parallel with the take-up step;
A method for producing a three-dimensional network structure comprising: An extrusion step of extruding and lowering the molten thermoplastic resin downward as a plurality of filaments;
The filaments contact the water surface, or contact a pair of guide members facing each other across the descending assembly of the filaments or a conveyor facing below the guide members, and the filaments are entangled irregularly. Loop formation step in which the entangled portion is heat-welded,
A take-off step comprising a guide for restricting bending in an inner region of an endless member provided around the conveyor, and holding the assembly by the conveyor and taking it into water at a speed slower than the descending speed of the filaments;
A cooling step for cooling the aggregate in water in parallel with the take-up step;
A method for producing a three-dimensional network structure comprising: An extrusion step of extruding and lowering the molten thermoplastic resin downward as a plurality of filaments;
The filaments contact the water surface, or contact a pair of guide members facing each other across the descending assembly of the filaments or a conveyor facing below the guide members, and the filaments are entangled irregularly. Loop formation step in which the entangled portion is heat-welded,
A take-off step comprising a guide for restricting bending in an inner region of an endless member provided around the conveyor, and holding the assembly by the conveyor and taking it into water at a speed slower than the descending speed of the filaments;
The endless member has a gap, and the cooling water is ejected through the gap from the inner area of the conveyor toward the take-up area sandwiched between the pair of conveyors, or the gap from the take-up area to the inner area of the conveyor. A cooling step in which forced convection of the water is caused by sucking water through and the assembly is cooled in water in parallel with the take-up step;
A method for producing a three-dimensional network structure comprising:   The method of manufacturing a three-dimensional network structure according to claim 7 or 8, wherein the guide is a circular guide that is provided coaxially with a rotating body that drives the endless member and restricts bending of the endless member.   The method of manufacturing a three-dimensional network structure according to claim 7 or 8, wherein the guide is an intermediate guide that extends in a circumferential direction of the endless member on a side of the inner region that contacts the assembly. The molten thermoplastic resin is extruded downward as a plurality of filaments,
The filaments contact the water surface, or contact a pair of guide members facing each other across the descending assembly of the filaments or a conveyor facing below the guide members, and the filaments are entangled irregularly. The entangled part is heat welded to form a loop,
The assembly is sandwiched by the conveyor and taken up in water at a speed slower than the descending speed of the filament,
An endless member provided around the conveyor has a gap, and cooling water is ejected from the inner area of the conveyor toward the take-up area sandwiched between the pair of conveyors through the gap or from the take-up area. A three-dimensional network structure in which forced convection of water occurs when water is sucked through the gap into the inner region of the conveyor and is cooled in water. The molten thermoplastic resin is extruded downward as a plurality of filaments,
The filaments contact the water surface, or contact a pair of guide members facing each other across the descending assembly of the filaments or a conveyor facing below the guide members, and the filaments are entangled irregularly. The entangled part is heat welded to form a loop,
A three-dimensional net-like structure in which the assembly is sandwiched by the conveyor provided with a guide for restricting bending in an inner region of an endless member provided around the conveyor, and is drawn into water and cooled at a speed lower than the descending speed of the filament. Structure. The molten thermoplastic resin is extruded downward as a plurality of filaments,
The filaments contact the water surface, or contact a pair of guide members facing each other across the descending assembly of the filaments or a conveyor facing below the guide members, and the filaments are entangled irregularly. The entangled part is heat welded to form a loop,
The assembly is sandwiched by the conveyor provided with a guide that regulates bending in an inner region of an endless member that is provided around the conveyor, and is taken up in water at a speed slower than the descending speed of the filament,
An endless member provided around the conveyor has a gap, and cooling water is ejected from the inner area of the conveyor toward the take-up area sandwiched between the pair of conveyors through the gap or from the take-up area. A three-dimensional network structure in which forced convection of water is caused by water being sucked through the gap to the inner region of the conveyor and is cooled in water.   The three-dimensional network structure according to claim 12 or 13, wherein the guide is a circular guide that is provided coaxially with a rotating body that drives the endless member and restricts bending of the endless member.   The three-dimensional network structure according to claim 12 or 13, wherein the guide is an intermediate guide that extends in a circumferential direction of the endless member on a side of the inner region that contacts the assembly.

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